Multilayer Abrasive Particle Curved Surface Geometry
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-layer abrasive particles have limited grinding performance due to their flat, right-angled surfaces and edges, which lead to reduced contact area and inconsistent wear patterns, affecting their efficiency and durability during grinding processes.
Innovation Solution
The abrasive particles are designed with partially convex and concave free surfaces and edges, and a shell-like structure that forms a spherical shape, optimizing the surface contact area and maintaining high grinding performance even during wear, achieved through controlled hardening processes and screen printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-layer abrasive particles are produced with flat, right-angled surfaces through conventional screen printing, then the manufacturing process is simple, but the grinding performance is limited due to reduced contact area and inconsistent wear patterns
Solution Approach 1:
The patent applies curvature to the free surfaces and edges of multi-layer abrasive particles, transforming flat, right-angled surfaces into convex and concave curved surfaces. This spheroidality principle increases the contact area with the workpiece during grinding, thereby improving grinding performance while maintaining the multi-layer structure produced by screen printing
2Productivity
If the free surfaces of abrasive particles are made convex and concave to increase contact area, then grinding performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent modifies the surface geometry parameters of the abrasive particles by introducing convex and concave deformations to the free surfaces and edges. These parameter changes in surface shape are achieved through controlled hardening processes that transform the particle morphology after screen printing, improving grinding performance without fundamentally changing the manufacturing process
3Ease of manufacture
If conventional hardening processes are used on flat multi-layer particles, then the production process is straightforward, but the surface area contact with abrasive material is insufficient
Solution Approach 1:
The patent performs surface deformation through controlled hardening as a preliminary action before the abrasive particles are fully utilized. By deforming the free surfaces and edges into convex and concave shapes during the hardening process, the contact surface area is increased in advance, ensuring better grinding performance from the outset
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the grinding performance by maintaining a consistent contact area with the material, reducing wear-induced performance degradation and improving the abrasive's efficiency and longevity.
Implementation Method 1
Sol-gel systems, for example, are suitable as the material system for the abrasive particles, in which the sol is extruded or printed in a state that is not removed from the gel point and a subsequent hardening to the abrasive particle takes place by transition to the gel state
Implementation Method 2
In the case of ceramic systems, a hardening step in the form of a calcining step can also be provided in order to finally harden the abrasive particles and to bring about the ceramic properties of the material system
Data Source
Figure 1~2
AI summary
The invention relates to a multilayer abrasive particle (01) having a layer structure of stacked layers (02), each of the layers (02) being formed parallel to a plane (E). The exposed surfaces (04) of the layers (02) not covered by another layer and/or the edges (08) connecting the exposed surfaces (04) extend at least partially convexly or concavely in relation to the plane (E) and/or to a plane (E2) that is perpendicular thereto and comprises the direction (03) of the layer thickness.